The installation and maintenance of this product must be done under the supervision of an experienced

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CPI 400 Valve Switch and Position Indicator Installation Instructions USA CDN Table of Contents Table of Contents...Page 1 Approvals...Page 1 Attention...Page 1 Specification.

..Page 4 Approvals Approval for this part is covered under the safety valve certification.

1 CPI 400 Valve Switch and Position Indicator Installation Instructions USA CDN Table of Contents Table of Contents...Page 1 Approvals...Page 1 Attention...Page 1 Specification...Page 2 Models Designations & Ranges...Page 2 Mounting....Page 2 Wiring...Page 3 Calibration & Testing...Page 3 Replacement Parts...Page 4 Approvals Approval for this part is covered under the safety valve certification. Attention The installation and maintenance of this product must be done under the supervision of an experienced and trained specialist. Never perform work if gas pressure or power is applied, or in the presence of an open flame. [V] [A] [Hz] [VA] Check the ratings in the specifications to verify that they are suitable for your application. 1 6 Explanation of symbols 1, 2, 3... = Action = Instruction Please read the instruction before installing or operating. Keep the instruction in a safe place. You find the instruction also at www. dungs.com. If these instructions are not heeded, the result may be personal injury or damage to property. Any adjustment and applicationspecific adjustment values must be made in accordance with the equipment manufacturers instructions. Safety first O.K. IFGC CSA UL ANSI NFPA On completion of work on the valve switch, perform a leakage and function test. This product is intended for installations covered by, but not limited to, the following codes and standards: NFPA 86, CSD-1, ANSI Z21.13, UL 795, NFPA 85 or CSA B149.3.

2 Specification CPI 400 Closed position indicator CPI 400 visually and eletrically indicates when the valve is either in the closed or open position. Mounts directly to the DMV, SV and MVD series valves. When the valve is closed a orange light is visible, when the valve is open a green light is visible. SPDT Ag [A] Switch Type SPDT Switch Action Valve open: Green light Valve closed: Orange light Contact Rating 10 A res, 8 FLA, VAC. 5 A 230 VAC. 1 A 24 VDC and 1 A VDC. When used, the 24 VDC/VAC indicator light consumes 20 ma when energized Enclosure NEMA Type 4 Gas Gases Dry, natural gas, propane, butane; other noncorrosive gases. Suitable for up to 0.1 % by volume, dry H 2 S when used with nickel plated brass adapter. A dry gas has a dew point lower than +15 F and its relative humidity is less than 60 %. NEMA Models Designations & Ranges Type Description Order No. CPI 400 Valve Switch Mounting 1. The valve must be de-energized and the gas supply shutoff before mounting the CPI. 2. Disconnect all power to the switch before beginning to prevent electrical shock and equipment damage. Mounting Procedure (reference Fig. 1) 3. IMPORTANT: Before mounting the brass adapter to the valve or to the CPI 400, use your fingers to verify that the pin slides freely inside the brass adapter. If this pin does not slide freely, apply a large enough force to the appropriate side to free the pin. 4. Using a 5mm hex wrench, remove the plug and its o-ring located at the bottom of the valve. 5. Verify that the brass adapter has a clean o-ring and its threads and the groove into which the brass adapter mounts, are clean and in good condition. 6. Mount the brass adapter into the valve. 7. Use a 9/16 (14 mm) open end wrench and torque to 44 in-lbs (5Nm), which is about 1/4 turn (after finger tight). DO NOT overtighten. 8. Mount the CPI switch onto the brass adapter. Push the CPI housing towards the valve until it stops. 9. Turn/Position the CPI so that the wiring and conduit connection apply the least amount of torque as possible. Breather plug (need not be vented) O-Ring Brass Adapter Set Screw Fig Tighten the set screw so that the CPI housing is secured to the brass adapter. 11. Do not turn the CPI 400 after tightening the set screw; this may strip the brass adapter. The brass adapter could loosen and the assembly may leak. 12. Perform a leak test to verify that no leakage occurs around the o-ring. 2 6

3 Wiring Required Wiring Do not exceed the switches electrical ratings. Use 14 or 16 gauge wire for at least 75 C (167 F). For NEMA 4 applications, NEMA 4 conduit or wiring methods must be used. Run one wire (the COMMON) to the L1 terminal, one to the GROUND terminal, one from the terminal 2 Proof Terminal to the Proof of Closure terminal of the Flame Safeguard, and one (the NEUTRAL) to L2 on the CPI 400. NOTE: If equipment neutral is not wired to L2 on the CPI 400, the lights will not properly indicate the valve position. The ORANGE light should be on when the valve is closed, The GREEN light should be on when the valve is open (FM and NFPA 86 requirement). L1 Com CPI 400 Switch Orange Lamp (valve closed) Green Lamp (valve opened) Flame Safeguard Proof of Closure terminal N L2 N CPI 400 Made in Germany Closed Position Indicator 3 L1; COM 1 Increment 2 Proof Terminal Red Wire 1 Yellow Wire Orange 3 6 Calibration & Testing Green Ground Fig. 2 The CPI 400 must be calibrated to the specific valve it is used on. Failing to properly calibrate this switch may lead to nuisance problems or to an unsafe startup condition. Calibrating the CPI: (Reference Fig. 2) 1. The CPI must be properly mounted to the valve, and the valve must be closed. 2. Disconnect all power to the CPI 400 before adjusting to prevent electrical shock and equipment damage. 3. Remove clear cover. 4. Turn the adjustment dial counterclockwise until it stops. 5. Then turn the adjustment dial clockwise until the switch makes. If there is too much noise to hear the switch trip, proceed to Calibrating the CPI in noisy environments. 6. Note the position of the set point in reference to the white lines on the scale. 7. Turn the adjustment dial two additional increments clockwise to the same relative position. 8. Replace clear cover, the CPI is now adjusted. Calibrating the CPI in noisy environments 1. Verify that there are no stray wires that are potentially a shock hazard while the dial is being manually adjusted. 2. Apply 120Vac to terminals L1 and L2 of the CPI. 3. Turn the adjustment dial counterclockwise until it stops. The GREEN light should be illuminated. Do not wire this switch to close a circuit that will directly power another safety shutoff valve. Doing so could result in a safety valve being energized and opened rather than emaining closed. 4. Then turn the adjustment dial clockwise until the RED light illuminates. 5. Note the position of the set point in reference to the white lines on the scale. 6. Turn the adjustment dial two additional increments clockwise to the same relative position. 7. Replace clear cover, and the CPI is now ready for serivce. Annual Testing 1. Perform a switch continuity test at least annually to verify that with the valves de-engerzied, the continuity between the switch contacts T3 (COM) and T2 (Proof Terminal) does not exceed 0.2 ohms, and verify that there is no continuity between the switch contacts T3 (COM) and T1. 2. Then, energize the valve, and verify that the continuity between the switch contacts T3 (COM) and T1 does not exceed 0.2 ohms, and then verify that there is no continuity between the switch contacts T3 (COM) and T2. 3. If any above check fails, do not use the CPI and contact DUNGS immediately.

Replacement Parts Kit Clear plastic cover (1 pcs) 240-837 Kit 120 VAC neon lights (one orange & one green) (1 pcs) 231-420 Kit 24 VAC/VDC neon lights (one red & one green) (1 pcs) 248-183 PG 11-1/2

4 Replacement Parts Kit Clear plastic cover (1 pcs) Kit 120 VAC neon lights (one orange & one green) (1 pcs) Kit 24 VAC/VDC neon lights (one red & one green) (1 pcs) PG 11-1/2 NPT conduit adapter (10 pcs) PG 11-1/2 NPT conduit adapter (1 pcs) Brass adapter (standard) Brass adapter (Ni plated) B CPI 400 valve switch A We reserve the right to make modifications in the course of technical development. Karl Dungs Inc Pheasant Ridge Drive NE Suite 150 Blaine, MN 55449, U.S.A. Phone Fax Internet Karl Dungs GmbH & Co. KG P.O. Box D Schorndorf, Germany Phone +49 (0) Fax +49 (0) Internet 4 6

5 USA CDN Replacement safety relevant components Austausch sicherheitsrelevanter Komponenten It is necessary to replace safety-relevant components after they have reached the end of their useful life. replacing such components according to the following table: Es besteht die Notwendigkeit sicherheitsrelevante Komponenten nach Erreichen ihrer Nutzungsdauer auszutauschen. Austausch gemäss folgender Tabelle: Valid only for domestic, residential and industrial* heating applications. *Not valid for high performance industrial heat process applications. See page 2 Gültig nur für häusliche Heizungsanlagen Nicht gültig für Thermprozessanwendungen mit Taktbetrieb Valve Type Safety relevant component Ventil Typ Sicherheitsrelevante Komponente Recommended replacement after years/cycles: Depends on the value which will be achieved first Empfohlener Austausch nach Jahren/Schaltspielen: Je nachdem welcher Wert zuerst erreicht wird [Years] [Rated Cycle Life (cycles)] Cycle Rate Schalthäufigkeit 5 6 [Jahre] Änderungen, die dem technischen Fortschritt dienen, vorbehalten We reserve the right to make modifications in the course of technical development. Karl Dungs Inc Pheasant Ridge Drive NE Suite 150 Blaine, MN 55449, U.S.A. Phone Fax info@karldungsusa.com Internet [Schaltspiele (auf/zu)] DMV-(D) SV-(D) MV(D)/602 1,000,000 cycles 500 /h DMV/MV/SV: 10 Years LE-Ausführungen 10 Jahre (mit Hydraulikbremse) 500,000 cycles 20 /h DMV/MV/SV: LE-Versions (with hydraulic brake) Gasventil mit DUNGS-Ventilprüfsystem Austausch nach erkanntem Fehler Replacement after error detection Gas valve with DUNGS valve proving system VPS 504* 20 /h 250,000 cycles VDK 200* 10 Years 15 /h CPI Jahre 1,000,000 1 A and 120 VAC CPI , A and 120 VAC 1,000 /h * Valve proving system values shown are expected lifetime. NFPA 86 does not require replacing if the expected life has been exceeded. Karl Dungs GmbH & Co. KG P.O. Box D Schorndorf, Germany Phone +49 (0) Fax +49 (0) info@dungs.com Internet

6 USA CDN Replacement safety relevant components Austausch sicherheitsrelevanter Komponenten It is necessary to replace safety-relevant components after they have reached the end of their useful life. replacing such components according to the following table: Es besteht die Notwendigkeit sicherheitsrelevante Komponenten nach Erreichen ihrer Nutzungsdauer auszutauschen. Austausch gemäss folgender Tabelle: Valid for high performance industrial heat process applications! Valve Type Safety relevant component Ventil Typ Sicherheitsrelevante Komponente Recommended replacement after years/cycles: Depends on the value which will be achieved first Empfohlener Austausch nach Jahren/Schaltspielen: Je nachdem welcher Wert zuerst erreicht wird [Years] [Rated Cycle Life (cycles)] Cycle Rate Schalthäufigkeit [Jahre] [Schaltspiele (auf/zu)] MV... /602 NPT 1/2 - NPT 2 (no main flow adjustment) MVD... /602 NPT 1/2 - NPT 1 (with main flow adjustment) 3 Years 3 Jahre 3,000,000 cycles 1,000 /h MVD... /602 NPT 11/4 - NPT 3 (with main flow adjustment) Conditions 1,000,000 cycles Clean gas (NG, LNG, LPG): maximum 50 micron gas filter required! Dry Gas: relative humidity < 60 % dew point of the gas < 14 F }"dry" Not valid for MV(D).../602 valves delivered before 2011/01 Änderungen, die dem technischen Fortschritt dienen, vorbehalten We reserve the right to make modifications in the course of technical development. Karl Dungs Inc Pheasant Ridge Drive NE Suite 150 Blaine, MN 55449, U.S.A. Phone Fax info@karldungsusa.com Internet Karl Dungs GmbH & Co. KG P.O. Box D Schorndorf, Germany Phone +49 (0) Fax +49 (0) info@dungs.com Internet 6 6

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